Perforated panel connection

ABSTRACT

A server enclosure having a plurality of panels abutted to one another and constrained by a connector having a channel and at least one aperture. Each respective panel has at least one perpendicular portion being perpendicular to a face of the respective panel and adjoining a perimeter of the respective panel. Connectivity media coincident to the aperture can affix at least two panels and a connector to one another.

BACKGROUND

The present disclosure relates to joining two or more components, andmore specifically, to joining two or more perforated components as partof a server enclosure.

SUMMARY

Aspects of the present disclosure relate to a method for fabricating ajoint. The method can comprise perforating at least a portion of a firstpanel and a second panel. The method can further comprise forming atleast one first perpendicular portion of the first panel and at leastone second perpendicular portion of the second panel, where eachrespective perpendicular portion has a surface perpendicular to a faceof the respective panel and coplanar to a plane formed by a thicknessand a portion of a perimeter of the respective panel. The method canfurther comprise abutting the first perpendicular portion to the secondperpendicular portion. The method can further comprise constraining thefirst perpendicular portion and the second perpendicular portion in achannel of a connector, where the connector comprises two approximatelyparallel surfaces connected by a third surface to form the channel, andwhere the third surface comprises at least one aperture comprising ageometry extruded through a thickness of the third surface to form atleast one void on the third surface of the connector. The method canfurther comprise affixing the first perpendicular portion, the secondperpendicular portion, and the connector.

Further aspects of the present disclosure can relate to a serverenclosure. The server enclosure can comprise a plurality of sidesforming an interior of the server enclosure, where the interior of theserver enclosure is configured to hold one or more servers. Each side ofthe server enclosure can comprise a plurality of panels. Each panel cancomprise a perforated face and at least one projection beingapproximately perpendicular to the perforated face and located on aportion of a perimeter of each respective panel. A plurality ofconnectors can adjoin each panel to at least one other panel, where eachconnector comprises a channel formed by a first portion parallel to asecond portion and connected by a third portion separating the firstportion and the second portion, and where the channel of each connectoris fitted over at least two abutted projections of at least two panels.Each third portion of each connector can comprise at least one aperturecomprising a void through a thickness of the third portion. A pluralityof connections can affix each connector to at least two panels, whereeach respective connection is coincident to a respective aperture.

Further aspects of the present disclosure can relate to a joint. Thejoint can comprise a first panel having a first face and a firstperpendicular portion and a second panel having a second face and asecond perpendicular portion. Each perpendicular portion can beapproximately perpendicular to a respective face and can be locatedalong a perimeter of a respective panel. Each perpendicular portion canbe perforated. The joint can further comprise a connector having achannel formed by a first surface connected to a second surface by athird surface. The third surface can comprise at least one aperture,where the at least one aperture can comprise a geometry extruded througha thickness of the third surface to create a void. The channel of theconnector can house the first perpendicular portion and the secondperpendicular portion abutted to one another for at least a firstportion of a length of the first perpendicular portion. The joint canfurther comprise at least one connectivity media connecting the firstpanel, the second panel, and the connector. The at least oneconnectivity media can be located coincident to the at least oneaperture.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included in the present application are incorporated into,and form part of, the specification. They illustrate embodiments of thepresent disclosure and, along with the description, serve to explain theprinciples of the disclosure. The drawings are only illustrative ofcertain embodiments and do not limit the disclosure.

FIG. 1 illustrates an example server rack in accordance with someembodiments of the present disclosure.

FIG. 2 illustrates an example portion of an enclosure in accordance withsome embodiments of the present disclosure.

FIGS. 3A-3C illustrate front, top, and side view of an example panel inaccordance with some embodiments of the present disclosure.

FIGS. 4A-4C illustrate front, bottom, and side views of an exampleconnector in accordance with some embodiments of the present disclosure.

FIGS. 5A and 5B illustrate cross-sectional and side views of a joint inaccordance with some embodiments of the present disclosure.

FIG. 6 illustrates a flowchart for a method for fabricating a connectionin accordance with some embodiments of the present disclosure.

While the present disclosure is amenable to various modifications andalternative forms, specifics thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit the presentdisclosure to the particular embodiments described. On the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the present disclosure.

DETAILED DESCRIPTION

Aspects of the present disclosure relate to joining two or morecomponents. More particular aspects relate to joining two or moreperforated components as part of a server enclosure. Although notlimited to such applications, an understanding of some embodiments ofthe present disclosure may be improved given the context of joining twoor more perforated components.

According to some embodiments of the present disclosure, each componentcan comprise a face having one or more perpendicular portions attachedto a perimeter of the face. In some cases, the one or more perpendicularportions can comprise a bent portion of the face (e.g., an approximately90-degree bend on a portion of the face that adjoins a perimeter of theface). In some embodiments of the present disclosure, a firstperpendicular portion is abutted to a second perpendicular portion andconstrained to one another by a connector. The connector can comprise afirst surface approximately parallel to a second surface and separatedby a distance defined by a third surface connecting the first surface tothe second surface. The first surface, second surface, and third surfacecan form a channel. In various embodiments, the cross section of thechannel can form a “U” shape or a “C” shape corresponding to acurvilinear or linear third surface, respectively. The connector canfurther comprise one or more apertures on the third surface. The one ormore apertures can comprise a geometry extruded through the thickness ofthe third surface such that a void is formed in the third surface (e.g.,a key-slot, groove, notch, perforation). The abutted perpendicularportions can be located in the channel and constrained by the firstsurface, the second surface, and the third surface of the connector. Theperpendicular portions can be affixed to the connector by a connectivitymedia being inserted into the one or more apertures of the connector andcreating a permanent, semi-permanent, or temporary bond between thefirst perpendicular portion, the second perpendicular portion, and theconnector.

In some embodiments, the joining of two or more components can be usedto form an enclosure. In some cases, the enclosure can comprise a serverrack. The server rack can be used to organize, store, and protect one ormore servers or other electronic components.

The server rack can contain numerous designs and mechanisms useful tomeeting structural, safety, thermal, electromagnetic compatibility(EMC), and other requirements. An example structural requirement can bea maximum load weight which can be safely stored in the enclosure. Anexample safety requirement can be no exposed edges in the enclosure. Anexample thermal requirement can be a maximum server rack interiortemperature. In such a case, holes, slots, or other geometriesbeneficial to increasing air flow through the server rack can be appliedto portions of the server rack to regulate the server rack temperature.In addition, geometries beneficial to modifying the surface area of theserver rack can result in non-linear, non-planar, or multi-planargeometries within and/or between portions of the server rack. An exampleof an EMC requirement can be emitting electromagnetic radiation below athreshold. For such a requirement, it can be beneficial to use ferrousenclosure materials and to decrease the amount of voids through whichelectromagnetic emissions can enter or escape the enclosure. Thus,design and fabrication of an enclosure such as a server rack can requirenumerous considerations in order to meet various structural, safety,thermal, EMC, and other requirements.

Various embodiments of the present disclosure can exhibit design andfabrication advantages beneficial to an enclosure such as a server rack.Firstly, the connector component can increase the structural strength ofan enclosure. Thus, components can be uniformly perforated withoutrequiring custom manufactured components to retain structural integrity.Secondly, the connector component can improve safety by covering sharpedges associated with cut perforated panels. When a standard perforatedpanel is cut to size, a perimeter of the standard perforated panel canhave numerous sharp portions which can lacerate and/or punctureequipment or users. Thirdly, the connector can consistently andaccurately locate connecting sites using the apertures in the connector.Fourthly, the connection can contain limited voids such thatelectromagnetic emissions escaping through, or entering through, theconnection are limited. Thus, in various embodiments, the connection ofthe present disclosure can decrease material and fabrication costs,increase safety, retain structural integrity, improve consistency, andreduce electromagnetic interference.

It is to be understood that the aforementioned advantages are exampleadvantages of various embodiments of the present disclosure. Thus, someembodiments of the present disclosure can exhibit none, some, or alladvantages listed hereinabove while remaining within the spirit andscope of the present disclosure. Furthermore, some embodiments of thepresent disclosure can exhibit additional advantages not listedhereinabove while remaining within the spirit and scope of the presentdisclosure.

Referring now to the drawings, FIG. 1 illustrates an example server rackin accordance with some embodiments of the present disclosure. Althoughthe present disclosure is applicable to alternative structures, FIG. 1will refer to a server rack in accordance with some embodiments of thepresent disclosure.

The server rack 100 can include one or more base supports 110 which cancomprise legs, wheels, or other base supports suitable for bearing theweight of the server rack 100, enabling movement of the server rack 100,leveling the server rack 100, dampening vibrations between theenvironment and the server rack 100, electrically isolating (e.g.,grounding) the server rack 100 from the environment, or otherwiseimproving various structural, ergonomic, and safety requirementsassociated with the server rack 100.

The server rack 100 can further comprise one or more panels 120A and120B (generally referred to as panel 120 herein). The panels 120 can, insome embodiments, contain perforations of a variety of geometries whichcan assist in air flow through, and thereby the cooling of, the serversoperating therein. In some cases, a single panel 120 forms a discreteside of the enclosure, while in alternative embodiments a plurality ofpanels 120 are used to form a discrete side of the enclosure. Respectivesides of an enclosure can be joined to one another at corners such ascorner 140. In some embodiments, portions of each respective panel 120adjoining a corner can be non-perforated. Although the panels 120A and120B are shown as being planar, the panels 120A and 120B can alsocomprise non-planar geometries such as, for example, curvilineargeometries. A panel 120A can be affixed to at least a second panel 120Band a connector (not shown) to form a joint 130. The connector can belocated on the inside portion of each pair of adjacent panels (e.g.,panel 120A and 120B). The underside of the front side of server rack 100containing panels 120A and 120B and forming joint 130 will be describedin further detail hereinafter with respect to FIG. 2.

Thus, FIG. 1 illustrates an example server rack in accordance with someembodiments of the present disclosure. Although the server rack 100 isshown as a rectangular shaped enclosure, numerous enclosure geometriesare contemplated including enclosures having different dimensions, morefaces, fewer faces, curvilinear faces, and other variations. Inaddition, various embodiments of the present disclosure can be used inapplications involving structures other than an enclosure or inenclosures other than server racks.

Referring now to FIG. 2, illustrated is an example portion of anenclosure in accordance with various embodiments of the presentdisclosure. The enclosure portion 200 can include a plurality of panelssuch as panels 210, 212, 214, 216, and 218. The panels can be similar ordissimilar shapes, and, in some cases, the panels can be perforated inwhole or in part. Each panel shares at least one side with at least oneother panel. The panels will be described in further detail hereinafterwith respect to FIG. 3.

Each pair of panels is connected by a connector such as connectors 220,222, 224, 226, and 228. Each connector can comprise a first surfaceparallel to a second surface and connected to one another by a thirdsurface. Thus, each connector can form a channel. Each connector caninclude one or more apertures which can be used to affix two panels anda connector to one another. The connectors will be described in furtherdetail hereinafter with respect to FIG. 4.

As an example, consider the panels 216 and 218 being connected byconnector 220. One edge of panel 216 is abutted to one edge of panel218. Connector 220 constrains the abutted edges of panel 216 and 218.Panel 216, panel 218, and connector 220 are then affixed to one anotherby a mechanical (e.g., fastener), chemical (e.g., adhesive), or other(e.g., weld) media or method suitable for affixing three components inthe geometry described. Techniques employed in affixing the variouscomponents are described in further detail hereinafter with respect toFIG. 5 and FIG. 6.

Referring now to FIG. 3, illustrated is an example panel in accordancewith various embodiments of the present disclosure. In some embodiments,the example panel described in FIG. 3 can be the same or substantiallythe same as panels 120A and 120B of FIG. 1 or panels 210, 212, 214, 216,or 218 of FIG. 2. FIG. 3 presents a top view 300, front view 310, andside view 320 of the example panel. For reference, the point 302 of thetop view 300 can be the same as point 312 of the front view 310 whichcan be the same as point 322 of the side view 320.

As can be seen in the top view 300, a panel face 304 can include aplurality of perforations. As can be seen in the front view 310, aperpendicular portion 314 of the panel can include a plurality ofperforations. As can be seen in side view 320, a second perpendicularportion 324 of the panel can have no perforations. Thus, according tovarious embodiments, each panel can have one or more perpendicularportions, and each panel can comprise one or more perforated portionsand one or more non-perforated portions. Although the perforations areshown as approximately circular, the perforations can be of any geometryor a combination of geometries.

Although not shown, the panel can contain ribs, flanges, or othergeometries providing structural, economic, or other benefits to thepanel. Furthermore, the panel can have projections, embossing,depressions, slots, notches, or other geometries beneficial to couplingthe panel to one or more other panels, connectors, or fasteners.

In various embodiments, the panels can comprise metallic, polymeric,composite, or other materials. Accordingly, the panels can bemanufactured by machining, forming, rolling, casting, molding, othermethods, or combinations of the aforementioned methods.

Referring now to FIG. 4, illustrated is an example connector inaccordance with some embodiments of the present disclosure. In someembodiments of the present disclosure, the connector illustrated anddescribed with respect to FIG. 4 can be the same or substantially thesame as the connectors 220, 222, 224, 226, and 228 of FIG. 2. FIG. 4illustrates a front view 400, a bottom view 410, and a side view 420.For reference, the point 402 of the front view 400 can be the same aspoint 412 of the bottom view 410 which can be the same as point 422 ofthe side view 420. As shown in the front view 400, the connector cancomprise two approximately parallel portions separated by a distance 408and connected by a third portion 406. The various portions can have athickness 404 which can be constant, approximately constant, or variableacross the various portions of the connector. As shown in the bottomview 410, the connector can include one or more apertures 414 creating avoid through the thickness 404 of the connector.

Although the cross-section of the aperture 414 is shown as beingrectangular, any number of geometries are possible which can havedifferent dimensions, more sides, fewer sides, or curvilinear sides.Furthermore, the connector can have ribs, flanges, or other geometriesbeneficial to increasing strength, decreasing weight, or achieving otherbenefits to the connector. Further still, although not shown, theconnector can have projections, embossing, depressions, slots, notches,or other geometries beneficial to coupling the connector to one or morepanels, other connectors, or fasteners.

In various embodiments, the connectors can comprise metallic, polymeric,composite, or other materials. Accordingly, the connectors can bemanufactured by a variety of methods such as machining, forming,casting, molding, other methods, or combinations of the aforementionedmethods.

Referring now to FIG. 5, illustrated is a joint in accordance with someembodiments of the present disclosure. FIG. 5 presents a cross-sectionalview 500 and a side view 520 of the joint. For reference, the point 502of the cross-sectional view 500 can be the same as point 522 of the sideview 520. Thus, the cross-sectional view 500 can correspond to a plane524 intersecting the side view 520 as shown. The joint can comprise afirst panel 504, a second panel 506, and a connector 508. The firstpanel 504 and the second panel 506 can be the same or substantially thesame as the panel shown and described with respect to FIG. 3 in someembodiments. The first panel 504 can comprise a first perpendicularportion 504A, and the second panel 506 can comprise a secondperpendicular portion 506A. The connector 508 can be the same orsubstantially the same as the connector described with reference to FIG.4, in some embodiments. The first perpendicular portion 504A can beabutted to the second perpendicular portion 506A. The two panels can beconstrained by a channel formed by connector 508. Connectivity media 510(also referred to herein as a connection) can be placed in a voidcreated by the first perpendicular portion 504A, the secondperpendicular portion 506A, and the connector 508. The connectivitymedia 510 can affix the first perpendicular portion 504A, the secondperpendicular portion 506A, and the connector 508 to one another. Theconnectivity media 510 can be applied over various lengths 528 andspaced at various intervals 526 as designated by the apertures of theconnector 508. Although the connectivity media 510 is shown as formingan approximately semi-circular cross section for an approximately linearlength 528, any number of geometries are contemplated while remainingwithin the spirit and scope of the present disclosure. In variousembodiments, numerous techniques and mechanisms can be used to connectthe first perpendicular portion 504A, the second perpendicular portion506A, and the connector 508 to one another. For example, theconnectivity media 510 can be a weld, an adhesive, or a mechanicalfastener, among others. As a result, the connectivity media 510 cancomprise a volume, a discrete component, or a component integrated ontoa panel or connector according to various embodiments of the presentdisclosure.

In cases where the connectivity media 510 comprises a weld, the weldingcan be performed by, for example, shielded metal arc welding (SMAW), gastungsten arc welding (GTAW), gas metal arc welding (GMAW), flux-coredarc welding (FCAW), submerged arc welding (SAW), electroslag welding(ESW), among others. In various applications, the welding energy can beproduced by gas, electricity, a laser, an electron beam, ultrasonicwaves, magnetic waves, friction, or other sources.

In cases where the connectivity media 510 comprises an adhesive, theadhesive can include, but is not limited to, drying adhesives (e.g.,solvent based adhesives or emulsion adhesives), pressure sensitiveadhesives (e.g., acrylate polymers having controlled molecular weights),contact adhesives (e.g., polymeric or elastomeric compounds undergoingpressure-induced strain crystallization such as polychloroprene),multi-part adhesives (e.g., reactive combinations of polyesters,polyurethanes, polyols, acrylics, epoxies, and other resins), one partadhesives (e.g., compounds or combinations thereof which react in thepresence of ultraviolet (UV) radiation, heat, moisture, or otherenvironmental factors), and others.

In cases where the connectivity media 510 comprises one or moremechanical fasteners, the one or more mechanical fasteners can include,but are not limited to, fasteners (e.g., screws, nails, bolts, rivets),push-fit or snap-fit components (e.g., clips, cotters, retaining rings,or custom interlocks), and other mechanical fastening methods andmechanisms such as shrink-fitting, interference-fitting, and others.

Referring now to FIG. 6, illustrated is a flowchart for a method forfabricating a joint or connection in accordance with some embodiments ofthe present disclosure. The method 600 can begin with operation 610 byperforating at least a portion of one or more panels. The perforationscan be any number of geometries such as, but not limited to, ovoidal,rectangular or other geometries.

In operation 620, at least one perpendicular portion can be formed foreach respective panel. The perpendicular portion can be formed along aperimeter of a panel. The perpendicular portion can be formed by bendinga portion of the panel adjoining the perimeter of the panel. Or, in someembodiments, the perpendicular portion can be a discrete portion whichis affixed to a portion of the perimeter of the panel. A face of theperpendicular portion can be coplanar to a face formed by a thickness ofthe panel and a portion of a perimeter of the panel. In variousembodiments, the panel shown and described with respect to FIG. 3 can bethe same or substantially the same as the panel created followingoperation 620.

In operation 630, two perpendicular portions of two panels can beabutted to one another. The perpendicular portions can be abutted suchthat a first perpendicular portion is substantially parallel to thesecond perpendicular portion, and furthermore, in some embodiments, suchthat one edge of a first perpendicular portion is approximatelycollinear to a second edge of the second perpendicular portion.

In operation 640, the abutted perpendicular portions can be constrainedby a connector such that the abutted perpendicular portions are housedin a channel formed by two parallel surfaces connected by a thirdsurface of the connector. The connector can house the two perpendicularportions for at least a portion of the length of the perpendicularportions. The connector can include one or more apertures forming one ormore voids on the third surface of the connector.

In operation 650, the first perpendicular portion, the secondperpendicular portion, and the connector can be affixed to one another.The first perpendicular portion, the second perpendicular portion, andthe connector can be affixed to one another by, for example, a weld, anadhesive, a mechanical fastener, or a different technique. The affixingcan be located coincident to one or more apertures of the connector. Insome embodiments, the affixing comprises interlocking the connector, thefirst perpendicular portion, and the second perpendicular portion to oneanother. The interlocking can be a function of one or more interlocks insome embodiments. The one or more interlocks can comprise projections,depressions, slots, or other geometries integrated into one or more ofthe connector, the first perpendicular portion, the second perpendicularportion, or other aspects of the joint or connection according tovarious embodiments of the present disclosure.

Thus, various aspects of the present disclosure relate to a connection,more particular aspects of the present disclosure relate to coupling twoor more perforated panels using a connector. The connection can provide,in various embodiments and among other benefits, improved strength,safety, and cost.

What is claimed is:
 1. A server enclosure comprising: a plurality ofsides forming an interior of the server enclosure, wherein the interiorof the server enclosure is configured to hold one or more serverstherein; wherein at least one side of the server enclosure comprises aplurality of panels, wherein each panel comprises a polymeric material,wherein each panel comprises a face having perpendicular portions ateach edge of a perimeter of the face and being perpendicular to theface, wherein the face is perforated and at least one of theperpendicular portions is not perforated, wherein each face of eachpanel comprises a triangular geometry; wherein a plurality of connectorsadjoin the plurality of panels to each other, wherein each connectorcomprises a composite material, wherein each connector comprises achannel formed by a first portion parallel to a second portion andconnected by a third portion separating the first portion and the secondportion, wherein the third portion comprises a variable thickness,wherein the channel of each connector is respectively fitted over atleast two respective and abutted ones of the perpendicular portions ofat least two of the plurality of panels, wherein each third portion ofeach connector comprises a plurality of apertures defining voids throughthe variable thickness of the third portion; and wherein a plurality ofconnections respectively affix each connector to the plurality ofpanels, wherein each connection is respectively coincident to respectiveones of said plurality of apertures, wherein each connection comprises avolume of polychloroprene.